Method and apparatus for increasing fatigue notch capability of airfoils

Abstract

A method of reducing crack propagation in an airfoil includes: providing an airfoil having a root spaced apart from a tip, spaced-apart leading and trailing edges, a suction side extending from the leading edge to the trailing edge, and an opposed pressure side extending from the leading edge and the trailing edge, supporting the airfoil against bending loads; and burnishing the airfoil using a burnishing element, so as to create at least one burnished section of residual compressive stress, the at least one burnished section being located adjacent the leading edge and spaced from the leading edge by an offset distance selected so as to avoid deformation of the leading edge.

Description

BACKGROUND OF THE INVENTION[0001]This invention relates generally to fatigue-resistant and damage-tolerant components and methods of producing such components.[0002]Various metallic, ceramic, and composite components, such as gas turbine engine fan and compressor blades, are susceptible to cracking from fatigue and damage (e.g. from foreign object impacts). This damage reduces the life of the part, requiring repair or replacement.[0003]It is known to protect components from crack propagation by inducing residual compressive stresses therein. Methods of imparting these stresses include shot peening, laser shock peening (LSP), pinch peening, and low plasticity burnishing (LPB). These methods are typically employed by applying a “patch” of residual compressive stresses over an area to be protected from crack propagation, for example a leading edge of a gas turbine engine compressor blade. However, shot peening is detrimental to the surface finish and has a lot of variation in its inten...

AI Technical Summary

Benefits of technology

[0004]The above shortcomings of the prior art, among others, are addressed by the present invention, which according to one aspect provides a method of reducing crack propagation in an airfoil, including: providing an airfoil having a root spaced apart from a tip, spaced-apart leading and trailing edges, a suction side extending from the leading edge to the trailing edge, and an opposed pressure side extending from the leading edge and the trailing edge; supporting the airfoil against bending loads; and burnishing the airfoil using a burnishing element, so as to create at least one burnished section of residual compressive stress, the at least one burnished section being located adjacent the leading edge and spaced from the leading edge by an offset distance selected so as to avoid deformation of the leading edge.

[0005]According to another aspect of the invention, an airfoil for a gas turbine engine includes: a root spaced apart from a tip, spaced-apart leading and trailing edges, a suction side extending from the leading edge to the trailing edge, and an opposed pressure side extending from the leading edge and the trailing edge, wherein a thickness of the airfoil is defined between the pressure side and the suction side; and at least one burnished section of residual compressive stress extending inward from a selected one of the pressure side and the suction sides. The burnished section is located adjacent the leading edge and spaced from the leading edge by an offset distance selected so as to avoid deformation of the leading edge.

Problems solved by technology

Various metallic, ceramic, and composite components, such as gas turbine engine fan and compressor blades, are susceptible to cracking from fatigue and damage (e.g. from foreign object impacts).

This damage reduces the life of the part, requiring repair or replacement.

However, shot peening is detrimental to the surface finish and has a lot of variation in its intensity even with industry standard control systems in place.

Parts like compressor airfoils lose their efficiency with rough surface finishes produced by shot peening.

Laser shock peening cans be expensive due to the required specimen preparation, equipment used, and personnel training requirements.

Furthermore, both shot peening and laser shock peening can be relatively slow processes.

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